APPRENTICESHIP TRAINING SCHEME (ATS) › images › ATS-Pump Opr Cum Mech...Apprenticeship Training Scheme (ATS) are two pioneer programmes of NCVT for propagating vocational training

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PUMP OPERATOR CUM MECHANIC COMPETENCY BASED CURRICULUM (Duration: 2 Yrs.)

APPRENTICESHIP TRAINING SCHEME (ATS)

NSQF LEVEL- 5

SECTOR – AGRICULTURE AND ALLIED SERVICES

GOVERNMENT OF INDIA MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP

DIRECTORATE GENERAL OF TRAINING

Pump Operator Cum Mechanic

PUMP OPERATOR CUM MECHANIC

(Revised in 2018)

APPRENTICESHIP TRAINING SCHEME (ATS)

NSQF LEVEL - 5

Developed By

Ministry of Skill Development and Entrepreneurship Directorate General of Training

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81, Sector-V, Salt Lake City,

Kolkata – 700 091


The DGT sincerely expresses appreciation for the contribution of the Industry, State

Directorate, Trade Experts and all others who contributed in revising the curriculum. Special

acknowledgement to the following industries/organizations who have contributed valuable

inputs in revising the curricula through their expert members:

1. Bokaro Power Supply Co. (P) Ltd.

2. Damodar Valley Corporation Ltd.,

3. Volkswagen Academy, Pune

4. OCL Ltd. (Dalmia Group), Odisha

5. Bharat Heavy Electricals Ltd., Ranipet, Tamil Nadu

6. TATA Motors, Pune

7. JBM Group, Chennai

8. MTAB Technology (P) Ltd., Chennai

Special acknowledgement is extended by DGT to the following expert members who had

contributed immensely in this curriculum.

Co-ordinator for the course: Sh. Nirmalya Nath., ADT, CSTARI- Kolkata

Sl.

No.

Name & Designation

Sh./Mr./Ms.

Organization Expert Group

Designation

1. R. N. Manna, T.O. CSTARI, Kolkata Expert

2. S. Bandypadhyay, T.O. ATI, Kolkata Member

ACKNOWLEDGEMENT


Sl.

No. Topics Page No.

1. Background 1-2

2. Training System 3-7

3. Job Role 8

4. NSQF Level Compliance 9

5. General Information 10

6. Learning Outcome 11-13

7. Learning Outcome with Assessment Criteria 14-16

8. Syllabus 17-23

9. Syllabus - Core Skill 24-32

9.1 Core Skill – Workshop Calculation & Science and

Engineering Drawing

9.2 Core Skill – Employability Skill

10. Details of Competencies (On-Job Training) 33-35

11. List of Trade Tools & Equipment Basic Training - Annexure I 36-45

12. Format for Internal Assessment -Annexure II 46

CONTENTS

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1.1 Apprenticeship Training Scheme under Apprentice Act 1961

The Apprentices Act, 1961 was enacted with the objective of regulating the

programme of training of apprentices in the industry by utilizing the facilities available

therein for imparting on-the-job training. The Act makes it obligatory for employers in

specified industries to engage apprentices in designated trades to impart

Apprenticeship Training on the job in industry to school leavers and person having

National Trade Certificate(ITI pass-outs) issued by National Council for Vocational

Training (NCVT) to develop skilled manpower for the industry. There are four

categories of apprentices namely; trade apprentice, graduate, technician and

technician (vocational) apprentices.

Qualifications and period of apprenticeship training of trade apprentices vary from

trade to trade. The apprenticeship training for trade apprentices consists of basic

training followed by practical training. At the end of the training, the apprentices are

required to appear in a trade test conducted by NCVT and those successful in the

trade tests are awarded the National Apprenticeship Certificate.

The period of apprenticeship training for graduate (engineers), technician (diploma

holders and technician (vocational) apprentices is one year. Certificates are awarded

on completion of training by the Department of Education, Ministry of Human

Resource Development.

1.2 Changes in Industrial Scenario

Recently we have seen huge changes in the Indian industry. The Indian Industry

registered an impressive growth during the last decade and half. The number of

industries in India have increased manifold in the last fifteen years especially in

services and manufacturing sectors. It has been realized that India would become a

prosperous and a modern state by raising skill levels, including by engaging a larger

proportion of apprentices, will be critical to success; as will stronger collaboration

between industry and the trainees to ensure the supply of skilled workforce and drive

development through employment. Various initiatives to build up an adequate

infrastructure for rapid industrialization and improve the industrial scenario in India

have been taken.

1. BACKGROUND

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1.3 Reformation

The Apprentices Act, 1961 has been amended and brought into effect from

22ndDecember, 2014 to make it more responsive to industry and youth. Key

amendments are as given below:

Prescription of number of apprentices to be engaged at establishment level instead of trade-wise.

Establishment can also engage apprentices in optional trades which are not designated, with the discretion of entry level qualification and syllabus.

Scope has been extended also to non-engineering occupations.

Establishments have been permitted to outsource basic training in an institute of their choice.

The burden of compliance on industry has been reduced significantly.

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2.1 GENERAL

Directorate General of Training (DGT) under Ministry of Skill Development &

Entrepreneurship offers range of vocational training courses catering to the need of different

sectors of economy/ Labour market. The vocational training programmes are delivered under

aegis of National Council of Vocational Training (NCVT). Craftsman Training Scheme (CTS) and

Apprenticeship Training Scheme (ATS) are two pioneer programmes of NCVT for propagating

vocational training.

PUMP OPERATOR CUM MECHANIC trade under ATS is one of the most popular courses

delivered nationwide through different industries. The course is of two years (02 Blocks)

duration. It mainly consists of Domain area and Core area. In the Domain area Trade Theory &

Practical impart professional - skills and knowledge, while Core area - Workshop Calculation and

science, Engineering Drawing and Employability Skills imparts requisite core skills & knowledge

and life skills. After passing out the training programme, the trainee is being awarded National

Apprenticeship Certificate (NAC) by NCVT having worldwide recognition.

Broadly candidates need to demonstrate that they are able to:

Read & interpret technical parameters/document, plan and organize work processes, identify necessary materials and tools;

Perform task with due consideration to safety rules, accident prevention regulations and environmental protection stipulations;

Apply professional skill, knowledge, core skills & employability skills while performing jobs and solve problem during execution.

Check the operation of pumps and valves as per specification for functioning, identify and rectify faults in it

Document the technical parameters related to the task undertaken.

2. TRAINING SYSTEM

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2.2 CAREER PROGRESSION PATHWAYS:

Indicative pathways for vertical mobility.

2.3 COURSE STRUCTURE:

Table below depicts the distribution of training hours across various course elements

during a period of two years (Basic Training and On-Job Training) :-

Total training duration details: -

Time (in months)

1-3 4-12 13-15 16-24

Basic Training Block– I ----- Block – II ------

Practical Training (On - job training)

---- Block – I ------ Block – II

A. Basic Training

For 02 yrs. course (Engg.) :-(Total 06 months: 03 months in 1styr. + 03 months in 2nd yr.)

For 01 yr. course (Engg.) :-(Total 03 months: 03 months in 1st yr.)

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S No. Course Element Total Notional Training Hours

For 02 Yrs.

course For 01 Yr.

course

1. Professional Skill (Trade Practical) 550 275

2. Professional Knowledge (Trade Theory) 240 120

3. Workshop Calculation & Science 40 20

4. Engineering Drawing 60 30

5. Employability Skills 110 55

Total (Including internal assessment) 1000 500

B. On-Job Training:-

For 02 yrs. Course (Engg.) :-( Total 18 months: 09 months in 1st yr. + 09 months in 2nd yr.)

Notional Training Hours for On-Job Training: 3120 Hrs.

For 01 yr. course (Engg.) :-( Total 12 months)

Notional Training Hours for On-Job Training: 2080 Hrs.

C. Total training hours:-

Duration Basic Training On-Job Training Total

For 02 yrs. course

(Engg.)

1000 hrs. 3120 hrs. 4120 hrs.

For 01 yr. course

(Engg.)

500 hrs. 2080 hrs. 2580 hrs.

2.4 ASSESSMENT & CERTIFICATION:

The trainee will be tested for his skill, knowledge and attitude during the period of course

and at the end of the training programme as notified by Govt of India from time to time. The

Employability skills will be tested in first two semesters only.

a) The Internal assessment during the period of training will be done by Formative assessment

method by testing for assessment criteria listed against learning outcomes. The training

institute have to maintain individual trainee portfolio as detailed in assessment guideline

(section-2.4.2). The marks of internal assessment will be as per the template (Annexure – II).

b) The final assessment will be in the form of summative assessment method. The All India Trade Test for awarding NAC will be conducted by NCVT on completion of course as per guideline of Govt of India. The pattern and marking structure is being notified by govt of India

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from time to time. The learning outcome and assessment criteria will be basis for setting question papers for final assessment. The examiner during final examination will also check individual trainee’s profile as detailed in assessment guideline (section-2.4.2) before giving marks for practical examination.

2.4.1 PASS REGULATION

The minimum pass percent for Practical is 60% & minimum pass percent for Theory subjects 40%. The candidate pass in each subject conducted under all India trade test.

2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial barriers to assessment. The nature of special needs should be taken into account while undertaking assessment. Due consideration should be given while assessing for team work, avoidance/reduction of scrap/wastage and disposal of scarp/wastage as per procedure, behavioral attitude, sensitivity to environment and regularity in training. The sensitivity towards OSHE and self-learning attitude are to be considered while assessing competency. Assessment will be evidence based comprising the following:

Job carried out in labs/workshop

Record book/ daily diary

Answer sheet of assessment

Viva-voce

Progress chart

Attendance and punctuality

Assignment

Project work

Evidences of internal assessments are to be preserved until forthcoming semester examination for audit and verification by examination body. The following marking pattern to be adopted while assessing:

Performance Level Evidence

(a) Weightage in the range of 60 -75% to be allotted during assessment

For performance in this grade, the candidate with occasional guidance and showing due regard for safety procedures and practices, has produced work which demonstrates attainment of an acceptable

Demonstration of good skill in the use of hand tools, machine tools and workshop equipment

Below 70% tolerance dimension/accuracy achieved while undertaking different work

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standard of craftsmanship.

with those demanded by the component/job/set standards.

A fairly good level of neatness and consistency in the finish

Occasional support in completing the project/job.

(b)Weightage in the range of above75% - 90% to be allotted during assessment

For this grade, the candidate, with little guidance and showing due regard for safety procedures and practices, has produced work which demonstrates attainment of a reasonable standard of craftsmanship.

Good skill levels in the use of hand tools, machine tools and workshop equipment

70-80% tolerance dimension/accuracy achieved while undertaking different work with those demanded by the component/job/set standards.

A good level of neatness and consistency in the finish

Little support in completing the project/job

(c) Weightage in the range of above 90% to be allotted during assessment

For performance in this grade, the candidate, with minimal or no support in organization and execution and with due regard for safety procedures and practices, has produced work which demonstrates attainment of a high standard of craftsmanship.

High skill levels in the use of hand tools, machine tools and workshop equipment

Above 80% tolerance dimension/accuracy achieved while undertaking different work with those demanded by the component/job/set standards.

A high level of neatness and consistency in the finish.

Minimal or no support in completing the project.

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Brief description of Job roles:

PUMP OPERATOR CUM MECHANIC; Pump Operator; Pump House Attendant; Pump

Driver; operates one or more power-driven machines for pumping, storing and supplying liquids

or other fluid materials or for dewatering purposes. Starts pump, observes its operation and

adjusts controls to maintain correct rate of pumping; stops pump when required quantity of

fluid has been moved; cleans, oils and greases pump, tightens loose parts and performs other

servicing tasks to keep pump and equipment in good running order and safe condition. May do

minor repairs. May connect pipe lines from pump to vessel to be filled or emptied. May be

designated according to type of pump operated or type of material (fluid) pumped, as PUMP

OPERATOR, STEAM PUMP OPERATOR, DIESEL; PUMP OPERATOR (ELECTRIC); TUBE WELL

OPERATOR.

Plan and organize assigned work and detect & resolve issues during execution. Demonstrate

possible solutions and agree tasks within the team. Communicate with required clarity and

understand technical English. Sensitive to environment, self-learning and productivity.

Reference NCO:

i) NCO-2015 :3132.0600 - Pump Station Operator, Waterworks

ii) NCO-2015-7233.1300 - Mechanic, Pump

3. JOB ROLE

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NSQF level for PUMP OPERATOR CUM MECHANIC trade under ATS: Level 5 As per notification issued by Govt. of India dated- 27.12.2013 on National Skill Qualification Framework total 10 (Ten) Levels are defined. Each level of the NSQF is associated with a set of descriptors made up of five outcome statements, which describe in general terms, the minimum knowledge, skills and attributes that a learner needs to acquire in order to be certified for that level. Each level of the NSQF is described by a statement of learning outcomes in five domains, known as level descriptors. These five domains are:

a. Process b. professional knowledge, c. professional skill, d. core skill and e. Responsibility.

The Broad Learning outcome of PUMP OPERATOR CUM MECHANIC trade under ATS mostly matches with the Level descriptor at Level- 5. The NSQF level-5 descriptor is given below:

Level Process

Required Professional Knowledge

Professional Skill Core Skill Responsibility

Level 5 Job that requires well developed skill, with clear choice of procedures in familiar context.

Knowledge of facts, principles, processes and general concepts, in a field of work or study

A range of cognitive and practical skills required to accomplish tasks and solve problem by selecting and applying basic methods, tools, materials and information.

Desired mathematical skill, understanding of social, political and some skill of collecting and organizing information, communication.

Responsibility for own work and Learning and some responsibility for other’s works and learning.

4. NSQF LEVEL COMPLIANCE

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Name of the Trade PUMP OPERATOR CUM MECHANIC

NCO – 2015 3132.0600, 7233.1300

NSQF Level Level – 5

Duration of Apprenticeship Training (Basic Training + On-Job Training)

Two years (02 Blocks each of one year duration).

Duration of Basic Training a) Block –I : 3 months b) Block – II : 3 months Total duration of Basic Training: 6 months

Duration of On-Job Training a) Block–I: 9 months b) Block–II : 9 months

Total duration of Practical Training: 18 months

Entry Qualification Passed 10th Class with Science and Mathematics under 10+2 system of Education or its equivalent

Selection of Apprentices The apprentices will be selected as per Apprenticeship Act amended time to time.

Instructors Qualification for Basic Training

As per ITI instructors qualifications as amended time to time for the specific trade.

Infrastructure for Basic Training As per related trades of ITI

Examination The internal examination/ assessment will be held on completion of each block. Final examination for all subjects will be held at the end of course and same will be conducted by NCVT.

Rebate to Ex-ITI Trainees 01 year

CTS trades eligible for PUMP OPERATOR CUM MECHANIC Apprenticeship


Note:

Industry may impart training as per above time schedule for different block, however this

is not fixed. The industry may adjust the duration of training considering the fact that all

the components under the syllabus must be covered. However the flexibility should be

given keeping in view that no safety aspects is compromised.

For imparting Basic Training the industry to tie-up with ITIs having such specific trade and

affiliated to NCVT.

5. GENERAL INFORMATION

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6.1 GENERIC LEARNING OUTCOME

The following are minimum broad Common Occupational Skills/ Generic Learning Outcome

after completion of the Pump Operator cum Mechanic course of 02 years duration under ATS.

Block I & II:-

1. Recognize & comply safe working practices, environment regulation and housekeeping.

2. Understand and explain different mathematical calculation & science in the field of

study including basic electrical. [Different mathematical calculation & science -Work,

Power & Energy, Algebra, Geometry & Mensuration, Trigonometry, Heat &

Temperature, Levers & Simple machine, graph, Power transmission, Pressure]

3. Interpret specifications, different engineering drawing and apply for different

application in the field of work. [Different engineering drawing-Geometrical

construction, Dimensioning, Layout, Method of representation, Symbol, scales, Different

Projections, Machined components & different thread forms, Assembly drawing,

Sectional views, Electrical& electronic symbol]

4. Select and ascertain measuring instrument and measure dimension of components and

record data.

5. Explain the concept in productivity, quality tools, and labour welfare legislation and

apply such in day to day work to improve productivity & quality.

6. Explain energy conservation, global warming and pollution and contribute in day to day

work by optimally using available resources.

7. Explain personnel finance, entrepreneurship and manage/organize related task in day to

day work for personal & societal growth.

8. Plan and organize the work related to the occupation.

6.2 SPECIFIC LEARNING OUTCOME

Block – I

1. Safety and best practices/Basic Industrial Culture (5S, KAIZEN, etc.)

2. Prepare different types of documentation as per industrial need by different methods of

recording information.

6. LEARNING OUTCOME

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3. Cutting, flaring of tubes to make T & Elbow fitting using unions. Fitting of lubrication

pump oil filters, air filters, checking and adjusting of oil pressure. Preventive

maintenance & repairing.

4. Familiarization with plain/journal bearings, anti-friction bearings used on machine

assembly. Specification mounting of bearing on shafts and in housing with proper fit &

axis alignment. Use of proper tools. Removal of bearings from s hafts & housing by

using pullers.

5. Cleaning up & removing old metal form bearing and replacing with new metal. Checking

of shafts for alignment with dial indicator.

6. Identification of different pumps, its components, prime movers. Practice on

operational safety dismantling of reciprocating pumps- valves, pistons, cranks, seals etc.

for inspection, repair & replacement. Cleaning of parts & assembling. Installing of

reciprocating pumps.

7. Dismantling of rotary pumps- impeller, shaft, bearing etc, for inspection, Repair &

replacement. Cleaning of parts and assembling. Checking for alignment, clearance, etc.,

Priming technique and its application. Installing, operating & testing of rotary pumps.

8. Servicing of pumps and valves of general purpose and of corrosive fluids. Selection of

gasket, packing & gland materials, marking & cutting off gasket as per shape & profile.

Using gasket cement to stop leakage & for fixing

9. Installation of seals leather polythene, asbestos, rope rubber and mechanical seals.

Maintenance of lubrication systems. Fitting of flanges and assembling of pipe work, leak

testing and rectification. Use of tee, elbow, bend, socket, rectifiers and other pipe

fittings. Cutting threads for pipes.

10. Reconditioning of centrifugal pumps.

11. Identifying and rectifying defects of pump sets. Practice on preventive & scheduled

maintenance of pump sets.

12. Making different types of keys for fitting pulleys, Assembling and dismantling of bushes, bearings and couplings maintaining safety.

Block – II

13. Dismantling identifying of parts, finding out defects, repairing, and replacement of

components, cleaning, assembling, installing and testing of submersible pumps. Finding

out & rectifying faults developed during operation.

14. Inspecting and Quality Controlling of finished products.

15. Material management and estimating the cost of repairing and reconditioning of pump

sets.

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16. Assembling and testing for correct function. Inspecting & rectifying causes of failure of

reciprocating, centrifugal, submersible, steam and vacuum pump.

17. Use of different types lifting tackles both mechanical and hydraulic such as - Screw jacks,

chain pulley block, crabs and winches, rollers and bars, levers, lashing and packing. Use

of inclined plane, hydraulic trolleys etc. Care and maintenance of lifting equipment

and safety to be observed by handling the equipment.

18. Installation of stationary & coupled pumps, checking and correcting of alignment of

pump with its prime movers and its serviceability test. Testing of pumps for their

delivery flow & pressure.

19. Oil engine filter repair services and overhauling of diesel or oil engines for efficient

performance.

20. Locating the faults to electric system and repairing the coil/rewinding.

21. Installation of assembled or repaired engine in position and connecting with propulsion

system.

22. Starting of engine ,tuning it up and observe performances noting of different reading

such as temperature, fuel level, oil pressure etc and setting it to specified standard for

optimum performance.

23. Checking, adjusting and lubricating engines periodically and performance testing.

24. Repairing and reconditioning of diesel, petrol, kerosene engines, electric motors &

steam turbine.

Note: Learning outcomes are reflection of total competencies of a trainee and assessment will

be carried out as per assessment criteria.

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GENERIC LEARNING OUTCOME

LEARNING OUTCOMES ASSESSMENT CRITERIA

1. Recognize & comply safe working practices, environment regulation and housekeeping.

1. 1. Follow and maintain procedures to achieve a safe working environment in line with occupational health and safety regulations and requirements.

1. 2. Recognize and report all unsafe situations according to site policy.

1. 3. Identify and take necessary precautions on fire and safety hazards and report according to site policy and procedures.

1. 4. Identify, handle and store / dispose off dangerous/unsalvageable goods and substances according to site policy and procedures following safety regulations and requirements.

1. 5. Identify and observe site policies and procedures in regard to illness or accident.

1. 6. Identify safety alarms accurately.

1. 7. Report supervisor/ Competent of authority in the event of accident or sickness of any staff and record accident details correctly according to site accident/injury procedures.

1. 8. Identify and observe site evacuation procedures according to site policy.

1. 9. Identify Personal Productive Equipment (PPE) and use the same as per related working environment.

1. 10. Identify basic first aid and use them under different circumstances.

1. 11. Identify different fire extinguisher and use the same as per requirement.

1. 12. Identify environmental pollution & contribute to avoidance of same.

1. 13. Take opportunities to use energy and materials in an environmentally friendly manner

1. 14. Avoid waste and dispose waste as per procedure

1. 15. Recognize different components of 5S and apply the same in the working environment.

2. Understand, explain different mathematical calculation & science in the field of study including basic

2.1 Explain concept of basic science related to the field such as Material science, Mass, weight, density, speed, velocity, heat & temperature, force, motion, pressure, heat treatment, centre of gravity, friction.

7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

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electrical and apply in day to day

work.[Different mathematical

calculation & science -Work,

Power & Energy, Algebra,

Geometry & Mensuration,

Trigonometry, Heat &

Temperature, Levers & Simple

machine, graph, Power

transmission, Pressure]

2.2 Measure dimensions as per drawing

2.3 Use scale/ tapes to measure for fitting to specification.

2.4 Comply given tolerance.

2.5 Prepare list of appropriate materials by interpreting detail drawings and determine quantities of such materials.

2.6 Ensure dimensional accuracy of assembly by using different instruments/gauges.

2.7 Explain basic electricity, insulation & earthing.

3. Interpret specifications, different engineering drawing and apply for different application in the field of work. [Different engineering drawing-Geometrical construction, Dimensioning, Layout, Method of representation, Symbol, scales, Different Projections, Machined components & different thread forms, Assembly drawing, Sectional views, Estimation of material, Electrical & electronic symbol]

3. 1. Read & interpret the information on drawings and apply in executing practical work.

3. 2. Read & analyse the specification to ascertain the material requirement, tools, and machining /assembly /maintenance parameters.

3. 3. Encounter drawings with missing/unspecified key information and make own calculations to fill in missing dimension/parameters to carry out the work.

4. Select and ascertain measuring instrument and measure dimension of components and record data.

4.1 Select appropriate measuring instruments such as micrometers, vernier calipers, and dial gauge (as per tool list).

4.2 Ascertain the functionality & correctness of the instrument.

4.3 Measure dimension of the components & record data to analyse the with given drawing/measurement.

5. Explain the concept in productivity, quality tools, and labour welfare legislation and apply such in day to day work to improve productivity & quality.

5.1 Explain the concept of productivity and quality tools and apply during execution of job.

5.2 Understand the basic concept of labour welfare legislation and adhere to responsibilities and remain sensitive towards such laws.

5.3 Knows benefits guaranteed under various acts

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6. Explain energy conservation, global warming and pollution and contribute in day to day work by optimally using available resources.

6.1 Explain the concept of energy conservation, global warming, pollution and utilize the available recourses optimally & remain sensitive to avoid environment pollution.

6.2 Dispose waste following standard procedure.

7. Explain personnel finance, entrepreneurship and manage/organize related task in day to day work for personal & societal growth.

7. 1. Explain personnel finance and entrepreneurship.

7. 2. Explain role of Various Schemes and Institutes for self-employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support agencies to familiarizes with the Policies /Programmes & procedure & the available scheme.

7. 3. Prepare Project report to become an entrepreneur for submission to financial institutions.

8. Plan and organize the work related to the occupation.

8. 1. Use documents, drawings and recognize hazards in the work site.

8. 2. Plan workplace/ assembly location with due consideration to operational stipulation

8. 3. Communicate effectively with others and plan project tasks

8. 4. Assign roles and responsibilities of the co-trainees for execution of the task effectively and monitor the same.

SPECIFIC OUTCOME

Block-I& II (Section:10)

Assessment Criteria i.e. the standard of performance, for each specific learning outcome mentioned under block – I & block – II(section: 10) must ensure that the trainee achieves well developed skill with clear choice of procedure in familiar context. Assessment criteria should broadly cover the aspect of Planning (Identify, ascertain, estimate etc.); Execution (perform, illustration, demonstration etc. by applying 1) a range of cognitive and practical skills required to accomplish tasks and solve problems by selecting and applying basic methods, tools, materials and information 2) Knowledge of facts, principles, processes, and general concepts, in a field of work or study 3)Desired Mathematical Skills and some skill of collecting and organizing information, communication) and Checking/ Testing to ensure functionality during the assessment of each outcome. The assessments parameters must also ascertain that the candidate is responsible for own work and learning and some responsibility for other’s work and learning.

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BASIC TRAINING (Block – I)

Duration: (03) Three Months

Week No.

Professional Skills (Trade Practical) Professional Knowledge (Trade Theory)

1.

Safety: - its importance, classification, personal, general, workshop and job safety. Occupational health and safety. Basic injury prevention, Basic first aid, Hazard identification and avoidance, safety signs for Danger, Warning, caution & personal safety message. Preventive measures for electrical accidents & steps to be taken in such accidents. Importance of housekeeping & good shop floor practices. Disposal procedure of waste materials like cotton waste, metal chips/burrs etc. Fire& safety: Use of Fire extinguishers

Importance of safety and general precautions observed in the in the industry/shop floor. All necessary guidance to be provided to the new comers to become familiar with the working of Institute system including stores procedures. Introduction of First aid. Safety attitude development of the trainee by educating him to use Personal Protective Equipment (PPE). Response to emergencies eg; power failure, fire, and system failure. Accidents- Definition types and causes. First-Aid, nature and causes of injury and utilization of first-aid. Introduction to 5S concept & its application. Fire: - Types, causes and prevention methods. Fire Extinguisher, its types. Global warming its causes and remedies. Industrial Waste its types, sources and waste Management.

2.

Identification of tools &equipments as per desired specifications related to the trade( Hand tools , Fitting tools & Measuring tools) Uses of marking tools, Punch, Try square & basic measuring tools, caliper, steel rule. Marking out lines, gripping suitably in vice jaws, hacksawing to given dimensions, sawing different types of metals of different sections.

HAND & POWER TOOLS:- Marking scheme, MARKING MATERIAL-chalk, Prussian blue. Cleaning tools- Scraper, wire brush, Emery paper, Description, care and use of Surface plates, steel rule, measuring tape, try square. Calipers-inside and outside. Dividers, surface gauges, scriber, punches-PRICK PUNCH, center punch, pin punch, hollow punch, number and

8. SYLLABUS

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Chipping flat surfaces and grinding various angles to chisels, filing flat surface. Grooving with Hammer and chisel. Marking and Drilling holes on flat pieces. Tapping as per simple drawing. Practice on General cleaning, checking and use of nut, bolts, & studs etc. Removal of stud/bolt from blind hole. Use of Lubrication, Cutting Threads on a Bolt/ Stud with die. Adjustment of two piece Die, Reaming a hole/ Bush to suit the given pin/ shaft, scraping a given machined surface.

letter punch. Chisel-flat, cross-cut. Hammer- ball pein, lump, mallet. Screw drivers-blade screwdriver, PHILLIPS screw driver, Ratchet screwdriver. Allen key, bench vice & C-clamps, Spanners- ring spanner, open end spanner & the combination spanner, universal adjustable open end spanner. Sockets & accessories, Pliers - COMBINATION PLIERS, MULTI GRIP, LONG NOSE, FLAT-NOSE, NIPPERS or pincer pliers, SIDE CUTTERS, TIN SNIPS, CIRCLIP PLIERS, EXTERNAL CIRCLIPS PLIERS. Air impact wrench, Air ratchet, wrenches- Torque wrenches, Pipe wrenches, Car jet washers Pipe flaring & cutting tool, pullers-Gear and bearing.

3-4 Identification of different pumps, its components, prime movers. Practice on operational safety Dismantling of reciprocating pumps- valves, pistons, cranks, seals etc. for inspection, repair & replacement. Cleaning of parts & assembling. Installing of reciprocating pumps.

Pump Industry in India - leading manufacturers, development in Pump Industry, trends, new product. Pumps-its importance for agricultural & industrial applications. Classification of pumps, its prime movers, parts and operation safety. Classification of reciprocating pump, construction and operation. Installation technique of reciprocating pump. Tools and equipment required & procedure.

5. Familiarization with plain/journal bearings, anti-friction bearings used on machine assembly. Specification Mounting of bearing on shafts and in housing with proper fit & axis alignment. Use of proper tools. Removal of bearings from s hafts & housing by using pullers. Cleaning up & removing old metal form bearing and replacing with new metal. Checking of shafts for alignment with dial indicator.

FASTENERS- Study of different types of screws, nuts, studs & bolts, locking devices, Such as lock nuts, cotter, split pins, keys, circlips, lock rings, lock washers and locating where they are used. Washers & chemical compounds can be used to help secure these fasteners. Function of GASKETS, Selection of materials for gaskets and packing, OIL

SEALS. CUTTING TOOLS Study of different type of

cutting tools like Hacksaw, File- Definition, parts of a file, specification, Grade, shape, different type of cut and uses., OFF-hand grinding with sander,

6-7 Dismantling of rotary pumps- impeller, shaft, bearing etc, for inspection, Repair &

Classification of rotary pumps- Construction and operation- repairing

19


replacement. Cleaning of parts and assembling. Checking for alignment, clearance, etc., Priming technique and its application. Installing, operating & testing of rotary pumps.

procedure. Brief description of turbine & stage pumps, positive displacements and their advantages. Meaning of priming and its effect. Installation techniques of rotary pump-procedure, tools and equipments required

8. Servicing of pumps and valves of general purpose and of corrosive fluids. Selection of gasket, packing & gland materials, marking & cutting off gasket as per shape & profile. Using gasket cement to stop leakage & for fixing

Different types of valves-their description, advantages & use. Special pumps & glands used for corrosive fluids. Different gasket cement used to prevent leakage and advantages of each over the other. Principle of direct reading pressure and temperature measuring instruments. Method to read and application of pressure and temperature measuring instruments

9. Practice on making out key as per shaft, hub, keyways, preparing keys to fit into keyways.

Types of key and key ways, their uses and applications. Preparation of keys, allowable tolerance, clearances. Key fitting procedure-methods. Procedure for removing keys. Types & uses of key pullers

10. Making different types of keys for fitting pulleys, Assembling and dismantling of bushes, bearings and couplings maintaining safety.

Types of pulleys solid, split, “V” groove, step, cone, taper, guided and jockey or rider pulleys, their functions and uses. Procedure to assemble and dismantle pulleys and impellers from shafts following safety precautions. Types of belt drives, velocity ratio of belt drive. Horse Power transmitted by belt. Ratio & driving tension in a belt. Parallel & cross belt drive, open & cross belt drive, angular belt drive. Methods of fixing and uses. Description, types and application of bushes, bearing and couplings. Procedure to fit bushes, bearings and coupling safely.

11. Installation of seals leather polythene, asbestos, rope rubber and mechanical seals. Maintenance of lubrication systems. Fitting of flanges and assembling of pipe work, leak testing and rectification. Use of tee, elbow, bend, socket, rectifiers and other pipe fittings. Cutting threads for

Various seals- their use and places of application with advantages. Lubrication types of lubricant use & methods of lubrication. Various tools and accessories used in pipe fitting with their details. Use of protecting caps on threads. Pipe fitting technique.

20


Note: - More emphasis to be given on video/real-life pictures during theoretical classes. Some

real-life pictures/videos of related industry operations may be shown to the trainees to give a

feel of Industry and their future assignment.

pipes. Procedure to fit flanges & for leak testing.

12.. Reconditioning of centrifugal pumps. Principle of centrifugal pump. Construction and operation of centrifugal pump in series and parallel. Finding out defects and method to recondition centrifugal pump.

13. Internal Assessment/Examination 03days

21


BASIC TRAINING (Block – II)

Duration: (03) Three Months

Week

No. Professional Skills (Trade Practical) Professional Knowledge (Trade Theory)

1. Installation of stationary & coupled pumps,

checking and correcting of alignment of

pump with its prime movers and its

serviceability test. Testing of pumps for

their delivery flow & pressure.

Reconditioning of centrifugal pumps.

Method of install, align and testing of

pumps for their serviceability. Concept

of lightening torque for different sizes

of bolts.

2-3. Dismantling identifying of parts, finding

out defects, repairing, and replacement of

components, cleaning, assembling,

installing and testing of submersible

pumps. Finding out & rectifying faults

developed during operation.

Submersible pump- construction,

operation and selection of appropriate

type. Procedure to recondition, install

and test of submersible pumps. Causes

of failures and remedial measures.

4. Identifying and rectifying defects of pump

sets. Practice on preventive & scheduled


Defects in pump sets- procedure for

detection of causes & rectification.

Purpose and procedure for balancing of

rotor. Procedure to be followed for

preventive & scheduled maintenance,

planning for spares and other stores.

5. Familiarization with the safety precautions

to be followed for electrical work.

Treatment for electrical shock. Use of hand

tools connected with electrical work and

maintenance of electrical machines.

Safety rules to be followed in

connection with electrical work. First

aid when affected by electrical shock.

Purpose, types, description and method

to use common electrical hand tools.

6. Verification of Ohm's law. Building up of

electrical series, parallel and combination

of series & parallel circuits.

Measurement of current, voltage

resistance. Exercise on fixing and

connecting switches holders, fuses, plugs

sockets, Push buttons, etc. Use of test

lamp and neon tester.

Identification of live, neutral and earthling

Description and method to use current,

voltage and resistance measuring

instruments and precaution to be

taken. Insulation Tester description,

method to use and precautions to be

taken. Alternating current- Definition

explanation and advantages over.

Direct current and vice-versa. Concept

and application of phase, star and delta

22


wires. Measurement of electrical power

and energy consumed for a definite period

of time.

connection. Procedure to identify live,

neutral, single phase and 3-phase

power supply. Method to measure

power and energy consumed by

electrical appliances using wattmeter

and Energy meter.

7. Identifying of A.C motors, their testing,

identifying terminals, connecting running &

reversing.

Measuring speed of A.C motor using

tachometer with stop watch. Dismantling,

assembling of A.C motors & identification

of parts.

Starting a single phase A.C motor with

Direct on line (D.O.L) starter. Starting a 3

phase motor with star-delta starter.

Checking for proper running of motor,

overheating etc. maintenance of motors

use and connection of single phase

preventor trouble shooting in circuit

AC Motors – related terminology.

Purpose, type, construction, operation,

testing for correct functioning,

maintenance and industrial

applications. Trouble shooting &

protection of induction motor.

8. Identifying, selecting, use of different types

of ropes such as hemp, manila, nylon, wire

etc.

Practicing different types of knots and its

applications. Method of joining two ropes,

Together for extension.

Detection of unsafe/defective conditions

of ropes and knots.

Use of different types lifting tackles both

mechanical and hydraulic such as – Screw

jacks, chain pulley block, crabs and

winches, rollers and bars, levers, lashing

and packing.

Care and maintenance of lifting equipment

and safety to be observed by handling the

equipment.

Specification and use of different types

of ropes such as hemp, manila, nylon,

wire etc.

Specification and correct use of slings.

Safety to be observed in use of ropes

and slings.

Description, operation, purpose,

application, care and use of Different

types of lifting tackles for components

of pump set. Precaution to be observed

while using lifting tackles.

23


Note: - More emphasis to be given on video/real-life pictures during theoretical classes. Some

real-life pictures/videos of related industry operations may be shown to the trainees to give a

feel of Industry and their future assignment.

9-10. Identification of different type of

stationary Engine and their applications.

Familiarisation with diesel engines, tools

and equipment required for maintenance,

engine parts and their handling technique.

Starting and stopping of engines.

Running of engines and checking

temperatures, fuel oil pressure and

consumption on load and engine speed

Principle of Compression-ignition

engine, Spark Ignition Engine,

differentiate between 4-stroke and 2

stroke, C.I engine and S.I Engine, Otto

cycle and Diesel cycle. Different type of

starting and stopping method of Diesel

Engine. Technical terms used in engine,

Engine specification

11. Cleaning of fuel tank, checking leaks in the

fuel lines. Cutting, flaring of tubes to make

T & Elbow fitting using unions. Fitting of

lubrication pump oil filters, air filters,

checking and adjusting of oil pressure.

Preventive maintenance & repairing

Procedure to clean fuel tank & check

leak in the fuel line. Lubrication system

– types, description and advantages of

each over others. Filters and oil coolers

– their description functions and

method to overhaul for efficient

functioning.

12. Practice on troubleshooting in for Engine

Not starting – Mechanical & Electrical

causes, High fuel consumption, Engine

overheating, Low Power Generation,

Excessive oil consumption, Low/High

Engine Oil Pressure, Engine Noise.

Troubleshooting : Causes and remedy

for Engine Not starting – Mechanical &

Electrical causes, High fuel

consumption, Engine overheating, Low

Power Generation, Excessive oil

consumption, Low/High Engine Oil

Pressure, Engine Noise.

13. Revision & Internal Assessment

24


9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING

Block – I

Sl. No.

Workshop Calculation and Science (Duration: - 20 hrs.)

Engineering Drawing (Duration : - 30 hrs.)

1. Units & Measurements- FPS, CGS, MKS/SI unit, unit of length, Mass and time. Fundamentals and derived units Conversion of units and applied problems.

Engineering Drawing: Introduction and its importance Different types of standards used in engineering drawing. Drawing Instruments: their uses Drawing board, T-Square, Drafter (Drafting M/c), Set Squares, Protractor, Drawing Instrument Box (Compass, Dividers, Scale, Diagonal Scales etc.), Pencils of different Grades, Drawing pins / Clips.

2. Material Science : properties -Physical & Mechanical, Types -Ferrous & Non-Ferrous, difference between Ferrous and Non-Ferrous metals

Lines : types and applications in Drawing as per BIS SP:46-2003 Drawing geometrical object using all types of lines. Drawing of Geometrical Figures: Angle, Triangle, Square, Rectangle and Circle. Letters: - Lettering styles, Single stroke letters and numbers as per IS standard. Lettering practice

3. Mass .Weight and Density : Mass, Unit of Mass, Weight, difference between mass and weight, Density, unit of density,

Dimensioning- Types of dimension, elements of dimensions, Methods of indicating Values, Arrangement, Alignment and indication of dimensions. Scales:-Types use and construction. Representative factor of scale.

4. Speed and Velocity: Rest and motion, speed, velocity, difference between speed and velocity, acceleration, retardation. Average Velocity, Acceleration & Retardation. Related problems. Circular Motion: Relation between circular motion and Linear motion, Centrifugal force, Centripetal force

Method of presentation of Engineering Drawing - Pictorial View - Orthogonal View - Isometric view

9. SYLLABUS - CORE SKILLS

25


5. Ratio &Proportion : Simple calculation on related problems. Percentage: Introduction, Simple calculation.

Constructions: - Draw proportionate free hand sketches of plane figures. Sketch horizontal, vertical and inclined line by free hand, Draw circles by free hand using square and radial line method, Draw arcs and ellipse by free hand

6. Work, Power and Energy: work, unit of work, power, unit of power, Horse power of engines, mechanical efficiency, energy, use of energy, potential and kinetic energy, examples of potential energy and kinetic energy. Meaning of H.P., I.H.P., B.H.P., and F.H.P. and CC and Torque.

Projections: Concept of axes plane and quadrant. Orthographic projections Method of first angle and third angle projections (definition and difference) Symbol of 1st angle and 3rd angle projection as per IS specification. Free hand Drawing of Orthographic projection from isometric/3D view of geometrical blocks

26


Block – II

Sl. No.

Workshop Calculation and Science (Duration: - 20 hrs.)

Engineering Drawing (Duration : - 30 hrs.)

1. Algebra: Addition, Subtraction, Multiplication, Division, Algebraic formula, Linear equations (with two variables).

Screw :- Its Types and Sizes, Screw thread, their standard forms as per BIS, external and internal thread.

2. Heat & Temperature: Heat and temperature, their units, difference between heat and temperature, boiling point, melting point, scale of temperature, relation between different scale of temperature, Thermometer, pyrometer, transmission of heat, conduction, convection, radiation.

Rivets and Joints:- Prepare a drawing sheet on rivets nomenclature and Joints.

3. Mensuration: Area and perimeter of square, rectangle, parallelogram, triangle, circle, semi circle, Volume of solids - cube, cuboid, cylinder and Sphere. Surface area of solids -cube, cuboid, cylinder and Sphere. Volume of cut-out solids: hollow cylinders, frustum of cone, block section. Volume of simple solid blocks.

Free hand Sketches for simple pipe line with general fittings.

4. Basic Electricity: Introduction, use of electricity, how electricity is produced, Types of current_ AC, DC, their comparison, voltage, resistance, their units. Conductor, insulator, Types of connections - series, parallel, electric power, Horse power, energy, unit of electrical energy. Concept of earthling.

Reading of drawing. Simple exercises related to missing lines, dimensions. How to make queries.

5. Simple machines Transmission of power: -Transmission of power by belt, pulleys & gear drive. Heat treatment process: - Heat treatment and advantages. Annealing, Normalizing, Hardening, Tempering.

Simple exercises related to trade related symbols. Basic electrical and electronic symbols

6. Trigonometry: Free hand sketch of trade related

27


Trigonometrical ratios, measurement of angles. Trigonometric tables. Finding the value of unknown sides and angles of a triangle by Trigonometrical method. Finding height and distance by trigonometry. Application of trigonometry in shop problems. (viz. taper angle calculation). Calculate the area of triangle by using trigonometry and application of Pythagoras theorem.

components / parts /cutting tool indicating angles.

7. Concept of pressure - Definition:-Force, Pressure, and their units, atmospheric pressure, gauges used for measuring pressure, problems. Introduction to pneumatics & hydraulics systems.

8. Simple exercises related to trade related Test Papers. Solution of NCVT test papers.

28


9.2 EMPLOYABILITY SKILLS (DURATION: - 110 HRS.)

Block – I (Duration – 55 hrs.)

1. English Literacy Duration : 20 Hrs. Marks : 09

Pronunciation Accentuation (mode of pronunciation) on simple words, Diction (use of word and speech)

Functional Grammar Transformation of sentences, Voice change, Change of tense, Spellings.

Reading Reading and understanding simple sentences about self, work and environment

Writing Construction of simple sentences Writing simple English

Speaking / Spoken English

Speaking with preparation on self, on family, on friends/ classmates, on know, picture reading gain confidence through role-playing and discussions on current happening job description, asking about someone's job habitual actions. Cardinal (fundamental) numbers ordinal numbers. Taking messages, passing messages on and filling in message forms Greeting and introductions office hospitality, Resumes or curriculum vita essential parts, letters of application reference to previous communication.

2. I.T. Literacy Duration : 20 Hrs. Marks : 09

Basics of Computer Introduction, Computer and its applications, Hardware and peripherals, Switching on-Starting and shutting down of computer.

Computer Operating System

Basics of Operating System, WINDOWS, The user interface of Windows OS, Create, Copy, Move and delete Files and Folders, Use of External memory like pen drive, CD, DVD etc, Use of Common applications.

Word processing and Worksheet

Basic operating of Word Processing, Creating, opening and closing Documents, use of shortcuts, Creating and Editing of Text, Formatting the Text, Insertion & creation of Tables. Printing document. Basics of Excel worksheet, understanding basic commands, creating simple worksheets, understanding sample worksheets, use of simple

29


formulas and functions, Printing of simple excel sheets.

Computer Networking and Internet

Basic of computer Networks (using real life examples), Definitions of Local Area Network (LAN), Wide Area Network (WAN), Internet, Concept of Internet (Network of Networks), Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page and Search Engines. Accessing the Internet using Web Browser, Downloading and Printing Web Pages, Opening an email account and use of email. Social media sites and its implication. Information Security and antivirus tools, Do's and Don'ts in Information Security, Awareness of IT - ACT, types of cyber crimes.

3. Communication Skills Duration : 15 Hrs. Marks : 07

Introduction to Communication Skills

Communication and its importance Principles of Effective communication Types of communication - verbal, non verbal, written, email, talking on phone. Non verbal communication -characteristics, components-Para-language Body language Barriers to communication and dealing with barriers. Handling nervousness/ discomfort.

Listening Skills Listening-hearing and listening, effective listening, barriers to effective listening guidelines for effective listening. Triple- A Listening - Attitude, Attention & Adjustment. Active Listening Skills.

Motivational Training Characteristics Essential to Achieving Success. The Power of Positive Attitude. Self awareness Importance of Commitment Ethics and Values Ways to Motivate Oneself Personal Goal setting and Employability Planning.

Facing Interviews Manners, Etiquettes, Dress code for an interview Do's & Don'ts for an interview.

Behavioral Skills Problem Solving Confidence Building Attitude

30


Block – II Duration – 55 hrs.

4. Entrepreneurship Skills Duration : 15 Hrs. Marks : 06

Concept of Entrepreneurship

Entrepreneur - Entrepreneurship - Enterprises:-Conceptual issue Entrepreneurship vs. management, Entrepreneurial motivation. Performance & Record, Role & Function of entrepreneurs in relation to the enterprise & relation to the economy, Source of business ideas, Entrepreneurial opportunities, The process of setting up a business.

Project Preparation & Marketing analysis

Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept & application of PLC, Sales & distribution Management. Different Between Small Scale &Large Scale Business, Market Survey, Method of marketing, Publicity and advertisement, Marketing Mix.

Institutions Support Preparation of Project. Role of Various Schemes and Institutes for self-employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support agencies to familiarizes with the Policies /Programmes & procedure & the available scheme.

Investment Procurement

Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation & Costing, Investment procedure - Loan procurement - Banking Processes.

5. Productivity Duration : 10 Hrs. Marks : 05

Benefits Personal / Workman - Incentive, Production linked Bonus, Improvement in living standard.

Affecting Factors Skills, Working Aids, Automation, Environment, Motivation - How improves or slows down.

Comparison with developed countries

Comparative productivity in developed countries (viz. Germany, Japan and Australia) in selected industries e.g. Manufacturing, Steel, Mining, Construction etc. Living standards of those countries, wages.

Personal Finance Management

Banking processes, Handling ATM, KYC registration, safe cash handling, Personal risk and Insurance.

6. Occupational Safety, Health and Environment Education Duration : 15 Hrs. Marks : 06

Safety & Health Introduction to Occupational Safety and Health importance of safety and health at workplace.

31


Occupational Hazards Basic Hazards, Chemical Hazards, Vibro acoustic Hazards, Mechanical Hazards, Electrical Hazards, Thermal Hazards. Occupational health, Occupational hygienic, Occupational Diseases/ Disorders & its prevention.

Accident & safety Basic principles for protective equipment. Accident Prevention techniques - control of accidents and safety measures.

First Aid Care of injured & Sick at the workplaces, First-Aid & Transportation of sick person.

Basic Provisions

Idea of basic provision legislation of India.

safety, health, welfare under legislative of India.

Ecosystem Introduction to Environment. Relationship between Society and Environment, Ecosystem and Factors causing imbalance.

Pollution Pollution and pollutants including liquid, gaseous, solid and hazardous waste.

Energy Conservation Conservation of Energy, re-use and recycle.

Global warming Global warming, climate change and Ozone layer depletion.

Ground Water Hydrological cycle, ground and surface water, Conservation and Harvesting of water.

Environment Right attitude towards environment, Maintenance of in -house environment.

7. Labour Welfare Legislation Duration : 05 Hrs. Marks : 03

Welfare Acts Benefits guaranteed under various acts- Factories Act, Apprenticeship Act, Employees State Insurance Act (ESI), Payment Wages Act, Employees Provident Fund Act, The Workmen's compensation Act.

8. Quality Tools Duration : 10 Hrs. Marks : 05

Quality Consciousness Meaning of quality, Quality characteristic.

Quality Circles Definition, Advantage of small group activity, objectives of quality Circle, Roles and function of Quality Circles in Organization, Operation of Quality circle. Approaches to starting Quality Circles, Steps for

32


continuation Quality Circles.

Quality Management System

Idea of ISO 9000 and BIS systems and its importance in maintaining qualities.

House Keeping Purpose of House-keeping, Practice of good Housekeeping.

Quality Tools Basic quality tools with a few examples.

33


BROAD LEARNING TO BE COVERED DURING ON – JOB TRAINING

1. Safety and best practices /Basic Industrial Culture (5S, KAIZEN, etc.)

2. Record keeping and documentation

3. Repairs pumps of process machinery: examines pumps for malfunctioning and to locate

damage or wear.

4. Carryout maintenance of different types of pumps & lifting tackles both mechanical and

hydraulic.

5. Repair and maintenance of Prime mover.

Note: Actual training will depend on the existing facilities available in the establishments.

The competencies/ specific outcomes on completion of On-Job Training are detailed

below: -

Block – I

1. Safety and best practices/Basic Industrial Culture (5S, KAIZEN, etc.)

2. Prepare different types of documentation as per industrial need by different methods

of recording information.

3. Cutting, flaring of tubes to make T & Elbow fitting using unions. Fitting of lubrication

pump oil filters, air filters, checking and adjusting of oil pressure. Preventive

maintenance & repairing.

4. Familiarization with plain/journal bearings, anti-friction bearings used on machine

assembly. Specification mounting of bearing on shafts and in housing with proper fit &

axis alignment. Use of proper tools. Removal of bearings from s hafts & housing by

using pullers.

5. Cleaning up & removing old metal form bearing and replacing with new metal.

Checking of shafts for alignment with dial indicator.

6. Identification of different pumps, its components, prime movers. Practice on

operational safety dismantling of reciprocating pumps- valves, pistons, cranks, seals

etc. for inspection, repair & replacement. Cleaning of parts & assembling. Installing of

reciprocating pumps.

7. Dismantling of rotary pumps- impeller, shaft, bearing etc, for inspection, Repair &

replacement. Cleaning of parts and assembling. Checking for alignment, clearance,

etc., Priming technique and its application. Installing, operating & testing of rotary

pumps.

10. DETAILS OF COMPETENCIES (ON-JOBTRAINING)

34


8. Servicing of pumps and valves of general purpose and of corrosive fluids. Selection of

gasket, packing & gland materials, marking & cutting off gasket as per shape & profile.

Using gasket cement to stop leakage & for fixing

9. Installation of seals leather polythene, asbestos, rope rubber and mechanical seals.

Maintenance of lubrication systems. Fitting of flanges and assembling of pipe work,

leak testing and rectification. Use of tee, elbow, bend, socket, rectifiers and other pipe

fittings. Cutting threads for pipes.

10. Reconditioning of centrifugal pumps.

11. Identifying and rectifying defects of pump sets. Practice on preventive & scheduled


12. Making different types of keys for fitting pulleys, Assembling and dismantling of

bushes, bearings and couplings maintaining safety.

Block – II

13. Dismantling identifying of parts, finding out defects, repairing, and replacement of

components, cleaning, assembling, installing and testing of submersible pumps.

Finding out & rectifying faults developed during operation.

14. Inspecting and Quality Controlling of finished products.

15. Material management and estimating the cost of repairing and reconditioning of

pump sets.

16. Assembling and testing for correct function. Inspecting & rectifying causes of failure of

reciprocating, centrifugal, submersible, steam and vacuum pump.

17. Use of different types lifting tackles both mechanical and hydraulic such as - Screw

jacks, chain pulley block, crabs and winches, rollers and bars, levers, lashing and

packing. Use of inclined plane, hydraulic trolleys etc. Care and maintenance of

lifting equipment and safety to be observed by handling the equipment.

18. Installation of stationary & coupled pumps, checking and correcting of alignment of

pump with its prime movers and its serviceability test. Testing of pumps for their

delivery flow & pressure.

19. Oil engine filter repair services and overhauling of diesel or oil engines for efficient

performance.

20. Locating the faults to electric system and repairing the coil/rewinding.

21. Installation of assembled or repaired engine in position and connecting with

propulsion system.

22. Starting of engine, tuning it up and observe performances noting of different reading

such as temperature, fuel level, oil pressure etc and setting it to specified standard for

optimum performance.

23. Checking, adjusting and lubricating engines periodically and performance testing.

35


24. Repairing and reconditioning of diesel, petrol, kerosene engines, electric motors &

steam turbine.

Note:

1. Industry must ensure that above mentioned competencies are achieved by the

trainees during their on job training.

2. In addition to above competencies/ outcomes industry may impart additional training

relevant to the specific industry.

36


INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL KNOWLEDGE


LIST OF TOOLS AND EQUIPMENT for Basic Training (For 20 Apprentices)

A. TRAINEES TOOL KIT ( For each additional unit trainees tool kit Sl. 1-19is required additionally)

Sl. no.

Name of the Tool &Equipment Specification Quantity

1 Allen Key Set of 12 pieces (2mm to

14mm) 6 Nos.

2 Caliper inside 15 cm Spring 6 Nos.

3 Calipers outside 15 cm spring 6 Nos.

4 Center Punch 10 mm. Dia. x 100 mm. 6 Nos.

5 Dividers 15 cm Spring 6 Nos.

6 Electrician Screw Driver 250mm 6 Nos.

7 Hammer ball peen 0.5 kg with handle 6 Nos.

8 Hands file 20 cm. Second cut flat 6 Nos.

9 Philips Screw Driver Set of 5 pieces (100 mm to

300 mm) 6 Nos.

10 Pliers combination 20 cm 6 Nos.

11 Screw driver 20cm.X 9mm. Blade 6 Nos.

12 Screw driver 30 cm. X 9 mm. Blade 6 Nos.

13 Scriber 15 cm 6 Nos.

14 Spanner D.E. Set of 12 pieces (6mm to

32mm) 6 Nos.

15 Spanner, ring Set of 12 metric sizes 6 to 32

mm 6 Nos.

16 Spanners socket with speed handle, T-bar, ratchet and universal

Upto 32 mm set of 28 pieces with box

6 Nos.

17 Steel rule 30 cm inch and metric 6 Nos.

18 Steel tool box with lock and key (folding type)

400x200x150 mm 6 Nos.

19 Wire cutter and stripper 15 cm 6 Nos.

B : INSTRUMENTS & GENERAL SHOP OUTFIT

20. Adjustable spanner (pipe wrench ) 350 mm 2 Nos.

ANNEXURE – I

37


21. Air blow sun with standard accessories 1 No.

22. Air impact wrench with standard accessories

4 Nos.

23. Air ratchet with standard accessories 4 Nos.

24. Allen Key set of 12 pieces (2mm to

14mm) 4 Nos.

25. Ammeter 300A/ 60A DC with external

shunt 4 Nos.

26. Angle plate adjustable 250x150x175 1 No.

27. Angle plate size 200x100x200mm 2 Nos.

28. Anvil with Stand 50 Kgs 1 No.

29. Auto Electrical test bench 1 No.

30. Battery -charger 2 Nos.

31. Bearing and gear tester 2 Nos.

32. Belt Tensioner gauge 1 No.

33. Blow Lamp 1 litre 2 Nos.

34. Bradawl 2 Nos.

35. Caliper inside 15 cm Spring 4 Nos.

36. Calipers outside 15 cm spring 4 Nos.

37. Cam lock type screw driver 1 No.

38. Car Jet washer with standard accessories 1 No.

39. Carge winches 3. 5 tonnes 1 No.

40. Chain pipe wrench 65 m 2 Nos.

41. Chain Pulley Block- with tripod stand 3 ton capacity 1 No.

42. Chisel 10 cm flat 4 Nos.

43. Chisels cross cut 200 mm X 6mm 4 Nos.

44. Circlip pliers Expanding and contracting type

15cm and 20cm each 4 Nos.

45. Clamps C 100mm 2 Nos.



48. Cleaning tray 45x30 cm. 4 Nos.

49. Compression testing gauge suitable for diesel Engine

2 Nos.

50. Copper bit soldering iron 25 W 5 Nos.

51. crab 1 No.

52. Cylinder bore aauae capacity 20 to 160 mm 4 Nos.

53. DC Ohmmeter, mid scales at 20 Ohms 0 to 300 Ohms 4 Nos.

38


54. Depth micrometer 0-2 5mm 4 Nos.

55. Dial gauge type 1 Gr. A (complete with clamping devices and stand)

4 Nos.

56. Different type of Engine Bearing model 1 set

57. Digital Tone Tester 0-20 A AC 2 Nos.

58. Dividers 15 cm Spring 4 Nos.

59. Drift Punch Copper 15 Cm 4 Nos.

60. Drill point angle gauge 1 No.

61. Drill twist (various sizes) by 0.5 mm 1.5 mm to 15 mm 4 Nos.

62. Electric Soldering Iron 230 V 60 watts 230 V 25

watts 2 each

63. Electric testing screw driver 2 Nos.

64. Energy meter AC. Single Phase. 5 Amps.

230 Volts 2 Nos.

65. Engineers square 700 mm 4 Nos.

66. Engineers stethoscope 1 No.

67. Feeler gauge (metric) 20 blades 4 Nos.

68. File flat ,bastard 20 cm 4 Nos.

69. File, half round ,second cut 20 cm 4 Nos.

70. File. Square, second cut 20 cm 4 Nos.

71. File. Square ,round 30 cm 4 Nos.

72. File, triangular ,second cut 15 cm 4 Nos.

73. Files assorted sizes and types including safe edge file (20 Nos)

2 set

74. Flat File ,second cut 25 cm 4 Nos.

75. Flat File bastard 35 cm 4 Nos.

76. Flow meter ,Itinin 0-400 2 Nos.

77. Forks clips 02 tonnes (copa) 1 No.

78. Forks clips 05 tonnes (copa) 1 No.

79. Foundation bolt 4 Nos.

80. Gasket hollow punches 5. 6. 8. 10. 12. 19. 25 mm

dia. l set

81. Glow plug tester 2 Nos.

82. Granite surface plate with stand and cover 1600 x 1000 1 No.

83. Grease Gun 2 Nos.

84. Growler 2 Nos.

85. Hacksaw frame adjustable 20-30 cm 10 Nos.

86. Hammer Ball Peen 0.75 Kg 4 Nos.

39


87. Hammer Chipping 0.25 Kg 4 Nos.

88. Hammer copper ,with handle 1 Kg 4 Nos.

89. Hammer Mallet 4 Nos.

90. Hammer Plastic 4 Nos.

91. Hand key way broacher 1 No.

92. Hand operated chain pulley block 1 No.

93. Hand operated crimping tool i) for crimping up to 4mm

and (ii) for crimping up to 10mm

2 Nos.

94. Hand reamers adjustable 10.5 to 11.25 mm. 11.25 to

12.75 mm. 12.75to 14.25 mm and 14.25 to 15.75 mm

2sets

95. Hand Shear Universal 250mm 2 Nos.

96. Hand vice - 37 mm 2 Nos.

97. Hollow Punch set of seven pieces 6mm to 15mm 2 sets

each

98. Hydraulic wheel and bearing puller 2 Nos.

99. Injector - Multi hole type Pintle type 4 each

100. Injector cleaning unit 1 No.

101. Injector testing set (Hand tester) 1 No.

102. Insulated Screw driver 20 cm x 9mm blade 4 Nos.

103. Insulated Screw driver 30 cm x 9mm blade 4 Nos.

104. Ladle 150mm Dia 1 No.

105. Left cut snips 250mm 4 Nos.

106. Level bottle (sprit). 150 ml 1 No.

107. Lifting jack screw type 3 ton capacity 4 Nos.

108. Magneto spanner set with S spanners 1 set

109. Magnifying glass 75mm 2 Nos.

110. Manila ropes 12. 20. 30 mm dia. 2 sets

111. Marking out table. 90X60X90 cm 1 No.

112. Masonry bit (Assorted up to 12 mm) 2set

113. Master test bars (different size) 1 No.

114. Meager 500 V 2 Nos.

115. Mobile crank 1 No.

116. Multimeter digital 5 Nos.

117. Oil can 0.5.0.25 liter capacity 2 Nos.

118. Oil Stone 15 cm x 5 cm x 2.5 cm 1 No.

119. Outside micrometer 0 to 25 mm 4 Nos.

40


120. Outside micrometer 25 to 50 mm 4 Nos.

121. Outside micrometer 50 to 75 mm 1 No.

122. Outside micrometer 75 to 100 mm 1 No.

123. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 2 sets

124. Pin spanner set 2 Nos.

125. Pipe cutting tool 2 Nos.

126. Pipe flaring tool 2 Nos.

127. Pipe wrench 45 mm 2 Nos.

128. Pliers combination 20 cm. 2 Nos.

129. Pliers flat nose 15 cm 2 Nos.

130. Pliers round nose 15 cm 2 Nos.

131. Pliers side cutting 15 cm 2 Nos.

132. Plumb bob 1 No.

133. Pneumatic scraper with adjustable stroke 2 Nos.

134. Portable electric drill Machine 1 No.

135. Portable jack 1 No.

136. Power Supply 0-12 v. lamp 1 No.

137. Pressure gauge 0 -5 Kg cm2 2 Nos.

138. Prick Punch 15 cm 4 Nos.

139. Punch Letter (Number) 4mm 2 set

140. Radius Gauge. Metric 2 Nos.

141. Ratchet chain pulley 1 No.

142. Rawl plug tool & kit 2 Nos.

143. Right cut snips 250mm 4 Nos.

144. Rivet sets snap and Dolly combined 3mm, 4mm, 6mm

4 Nos.

145. Rollers (steel tubes). from 40 to 65 mm dia 5 Nos.

146. Rotary pump working for dismantling and assembling

1 No.

147. Scientific Calculator 2 Nos.

148. Scraper flat 25 cm 2 Nos.

149. Scraper half round 25 cm 2 Nos.

150. Scraper Triangular 25 cm 2 Nos.

151. Screw jacks 1 No.

152. Scriber 15 cm 2 Nos.

153. Scriber with scribing black universal 2 Nos.

154. Self alignment roller ball bearing 2 Nos.

41


155. Set of stock and dies - Metric 2 sets

156. Shear legs (tripod) 1 No.

157. Shear Tin Man's 450 mm x 600mm 4 Nos.

158. Sheet Metal Gauge 2 Nos.

159. squirrel gage Induction motor

Single Phase 220 V Capacitor type AC Motor

1 No.

160. Soldering Copper Hatchet type 500 gms 4 Nos.

161. Solid Parallels in pairs (Different size) in Metric

4 Nos.

162. Spanner Clyburn 15 cm 1 No.

163. Spanner D.E. set of 12 pieces (6mm to

32mm) 4 Nos.

164. Spanner T. flocks for screwing up and up-screwing inaccessible

2 Nos.

165. Spanner, adjustable 15cm. 2 Nos.

166. Spanner, ring

set of 12 metric sizes 6 to 32 mm. 2 Nos.

167. Spanners socket with speed handle. T-bar. ratchet and universal upto

2 Nos.

168. Spark lighter 2 Nos.

169. Spark plug spanner 14mm x 18mm x Size 2 Nos.

170. Square box wrenches 1 No.

171. Square T-wrenches 1 No.

172. SRDG ball bearing. DRDG ball bearing, self aligning ball bearing.

1 No.

173. Steel measuring tape 10 meter in a case 4 Nos.

174. Steel rule ,inch and metric 15 cm 4 Nos.

175. Steel rule ,inch and metric 30 cm 4 Nos.

176. Steel wire Brush 50mmx 150mm 5 Nos.

177. Straight edge gauge 2 ft. 2 Nos.

178. Straight edge gauge 4 ft. 2 Nos.

179. Stud extractor set of 3 2 sets

180. Stud remover with socket handle 1 No.

181. Surface gauge with dial test indicator plunger type i.e. 0.01 nun

1 No.

182. Tachometer (Counting type) 1 No.

183. Taps and Dies complete sets (5 types) 1 set

184. Taps and wrenches - UNC, UNF and metric 2 sets

185. Telescope gauge 4 Nos.

42


186. Temperature gauge 0-100 de ac 2 Nos.

187. Thermostat 2 Nos.

188. Thimbles of different sizes 2 Nos.

189. Thread pitch gauge Metric. 1 No.

190. Threaded fastener type B 2 Nos.

191. Threaded fastener type C 2 Nos.

192. Threaded fastener type F 2 Nos.

193. Three cell torch 2 Nos.

194. Squirrel gage induction motor with star delta starter

Three Phase 50 Hz. 5 HP AC 1 No.

195. Timing lighter 1 No.

196. Torque wrenches 5-35 Km. 12-68 km & 50-225

Km 1 each

197. Trammel 30 cm 2 Nos.

198. Travelling and gantry cranes 1 No.

199. Tube expander up to 62 mm 1 No.

200. Universal puller for removing pulleys, bearings

1 No.

201. V" Block ,pair with Clamps 75 x 3S mm 2 Nos.

202. Vacuum gauge to read 0 to 760 mm of Hg. 2 Nos.

203. Vernier caliper 0-300 mm with least count

0.02mm 4 Nos.

204. Vibrometer 2 Nos.

205. Vice grip pliers 2 Nos.

206. Voltmeter AC 0 to 500 V 2 Nos.

207. Wall hoists 1 No.

208. Water pump for dismantling and assembling

2 Nos.

209. Wattmeter AC DC. 0 to 10 K\v 2 Nos.

210. Wire Gauge (metric) 5 Nos.

211. Work bench 250 x 120 x 60 cm with 4

vices 12cm Jaw 1 No.

C : GENERAL MACHINERY INSTALLATIONS

1 Arbor press hand operated 2 ton capacity 1 No.

2 Back pull out type centrifugal pump 1 No.

3 Bench lever shears 250mm Blade x 3mm

Capacity 1 No.

4 Centrifugal pump coupled with mono block set

1 No.

43


5 Diesel engine 2 stroke vertical (up to 10

KW ISHP) 1 No.

6 Diesel Engine 4 stroke vertical (up to about 10 KW ISHP) 1 No.

7 Diesel Engine Driven portable pump set 1 No.

8 Diesel Engine ,fitted with pump Upto 3.5 KW . 4.5 HP 1 No.

9 Discrete Component Trainer Basic Electronics Trainer

1 No.

10 Drilling machine bench to drill ,along with accessories

up to 12inm dia 1 No.

11 Dual Magnetization Yoke AC: HWDC 230 VAC. 50Hz 1 set

12 Gas Welding Table 1220mm x760nini 2 Nos.

13 Grinding machine (general purpose) D.E. pedestal

300 mm dia wheels rough and smooth

1 No.

14 Horizontal split casing pump 1 No.

15 Hydraulic jack HI-LIFT type 3 ton capacity. 1 No.

16 Hydraulic Leak Testing equipment 1 No.

17 Injector Testing set (Hand Tester) 1 No.

18 Liquid penetrant Inspection kit 1 set

19 Multi stage pump 1 No.

20 Overhead tank. pump, with level indicators and piping layout

minimum 5000 litters 1 No.

21 Pipe Bending Machine (Hydraulic type) 12mm to 30mm 1 No.

22 Pneumatic rivet gun 1 No.

23 Portable electric drill Machine 1 No.

24 Reciprocating Pump working for dismantling and assembling

1 No.

25 Spring tension tester 1 No.

26 Submersible pump set, eight stage upto 10 KW7 15 HP 1 No.

27 Tin smiths bench folder 600 x 1.6mm 1 No.

28

Trolley type portable air compressor single cylinder

45 liters capacity Air tank, along with accessories & with working pressure 6.5 kg sq cm

1 No.

29 Welding plant Oxy-Acetylene complete (high pressure)

1 No.

30 Welding Transformer ( 150-300 Amps) 1 No.

Note: In case of basic training setup by the industry the tools, equipment and machinery

available in the industry may also be used for imparting basic training.

44


INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND ENGINEERING DRAWING

TRADE: PUMP OPERATOR CUM MECHANIC

LIST OF TOOLS& EQUIPMENTS FOR -20APPRENTICES

1) Space Norms : 45 Sq.m. (For Engineering Drawing)

2) Infrastructure:

A : TRAINEES TOOL KIT:-

Sl.

No. Name of the items Specification Quantity

1. Draughtsman drawing instrument box 20 Nos.

2. Set square celluloid 45⁰ (250 X 1.5 mm) 20 Nos.

3. Set square celluloid 30⁰-60⁰ mm) (250 X 1.5 20 Nos.

4. Mini drafter 20 Nos.

5. Drawing board IS: 1444 (700mm x500 mm) 20 Nos.

B : Furniture Required

Sl.

No. Name of the items Specification Quantity

1 Drawing Board 20 Nos.

2 Models : Solid & cut section as required

3 Drawing Table for trainees as required

4 Stool for trainees as required

5 Cupboard (big) 01

6 White Board (size: 8ft. x 4ft.) 01

7 Trainer’s Table 01

8 Trainer’s Chair 01

45


TOOLS &EQUIPMENTS FOR EMPLOYABILITY SKILLS

Sl. No. Name of the Equipment Quantity

1. Computer (PC) with latest configurations and Internet connection with standard operating system and standard word processor and worksheet software

10 Nos.

2. UPS - 500VA 10 Nos.

3. Scanner cum Printer 1 No.

4. Computer Tables 10 Nos.

5. Computer Chairs 20 Nos.

6. LCD Projector 1 No.

7. White Board 1200mm x 900mm 1 No.

Note: - Above Tools &Equipments not required, if Computer LAB is available in the institute.

46


Name & Address of the Assessor : Year of Enrollment :

Name & Address of ITI (Govt./Pvt.) : Date of Assessment :

Name & Address of the Industry : Assessment location: Industry / ITI

Trade Name : Semester: Duration of the Trade/course:

Learning Outcome:

Sl. N

o

Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

Tota

l in

tern

al a

sse

ssm

ent

Mar

ks

Res

ult

(Y

/N)

Candidate Name Father's/Mother’s

Name

Safe

ty c

on

scio

usn

ess

Wo

rkp

lace

hyg

ien

e

Att

end

ance

/ P

un

ctu

alit

y

Ab

ility

to

fo

llow

Man

ual

s/ W

ritt

en

inst

ruct

ion

s

Ap

plic

atio

n o

f K

no

wle

dge

Skill

s to

han

dle

to

ols

&

equ

ipm

ent

Eco

no

mic

al u

se o

f m

ater

ials

Spee

d in

do

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wo

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1

2

FORMAT FOR INTERNAL ASSESSMENT

ANNEXURE-II